Nissan PULSAR N13 Series / ASTRA LD Series. Manual - part 13

Engine

Method of checking cylinder head for distortion.

(3) Carefully clean the deposits from the inlet

and exhaust ports, the auxiliary passages, the valve
guides and the manifolds, taking care not to damage
any mating surfaces.

(4) Clean the cylinder head mounting faces,

wash the cylinder head in solvent and dry with
compressed air. Blow through all the oil holes with
compressed air to ensure that they are not blocked.

(5) Check the cylinder head for distortion diag-

onally and lengthwise using a straight edge and feeler
gauges. Refer to Specifications for the distortion and
machining limits.

(6) Check the cylinder head face and combus-

tion chambers for cracks, burn marks and corrosion.

(7) Check the valve stem to guide clearance. If

the clearance is in excess of the Specifications, the
valve guide must be reamed and the appropriate
oversize valve installed.

(8) Inspect the valve seats for pitting or burning

and if necessary, recut the seats with a valve seat
cutter to the recommended angle. When the seats are
correctly finished, the seat widths should conform to
the Specifications.

(9) Lap the valves to the valve seats with a fine

lapping compound. Apply a smear of Prussian blue to
the valves or their respective seats to ensure that true
and concentric seating has been gained.

(10) Install each valve in its respective port

and
check the valve stem height above the cylinder head.
Refer to the illustration. The extended height must
not exceed 18.4 mm. If the height exceeds the
Specifications, the valve or the cylinder head must be
renewed. Do not remove any material from the valve
stem tip.

(11) Check the valve spring tensions and compare

with the Specifications.

Check that the springs are not bent or distorted.

If a spring tester is not available, check the springs

by comparison with new springs. This can be done
using a surface plate and straight edge for checking the
free length and using a new spring and a used spring
loaded in a vice end on end, with a plate in between.
Measure from the plate to the vice jaw adjacent to
both the new and used springs. A used spring is
serviceable if it does not show collapse in excess of
five percent when subjected to this comparison test.

(12) Check the exhaust valve rotators for wear

and ensure that the rotators turn freely.

(13) Clean the cylinder block face of all carbon

and rust deposits and ensure that all old gaskets are
removed. Do not allow the waste deposits to enter the
oil or water galleries.

Clean all waste materials from the cylinder bores.

TO ASSEMBLE

Assembly is a reversal of the dismantling proce-

dure with attention to the following points:

(1) Lubricate all component wear surfaces with

engine oil before assembly to ensure adequate lubri-
cation when starting.

(2) If the oil pressure relief valve was removed

from the cylinder head, proceed as follows:

(a) Using a brass tube inserted in the welch plug

hole at the distributor end of the cylinder head, tap
the relief valve into position.

(b) Install the welch plug and the recessed screw

in their respective positions, after coating the plug and
the screw with Loctite 242 or equivalent.

(3) Install the inlet valve spring seats and

the
exhaust valve rotators over the valve guides before
installing the valve stem seals onto the valve guides.

(4) Install the valve stem seals, ensuring that

the
rib of the moulding on the inside of the seal is
correctly positioned in the groove of the valve guide
and that the spring clip retainer is correctly posi-
tioned.

NOTE: The valve stem seals can be posi-
tioned correctly and without damage using
an upturned valve spring retainer.

(5) Install the valves to their original location in

the cylinder head. Use care when installing the valves
to prevent damage to the seals.

(6) Install the valve springs, retainers and

collets.
Ensure that the valve retaining collets are fully seated

Dimension A is the correct position to measure the
valve stem installed height. Dimension A = 18.4 mm.

Engine

in the valve stem groove before releasing the spring
compressor. A sharp tap to the top of the valve stem
with a soft faced hammer will ensure that the collets
are correctly seated.

(7) Install the inlet and exhaust manifolds using

new gaskets and tighten the mounting nuts to the
specified torque as previously described.

(8) Install a new sealing ring to the

thermostat
housing, install the housing to the cylinder head and
tighten the mounting bolts to the specified torque.

(9) Ensure that the lappet assemblies are filled

with clean engine oil and install the tappets in
their
respective bores in the cylinder head.

(10) Install the thrust pads to the top of each

valve
assembly, ensuring that they are returned to their
original locations.

(11) Coat the contact surfaces of the rocker arms

with molybdenum disulphide grease and install the
rocker arms to their original locations on the cylinder
head.

(12) Install the cylinder head to the engine as

previously described.

8. ENGINE SUMP AND OIL PUMP PICKUP

. PIPE

TO REMOVE

(1) Disconnect the negative battery terminal.
(2) Raise the front of the vehicle and support it

on chassis stands. Refer to the Wheels and Tires
section for the correct procedure.

(3) Remove the sump plug and drain the engine

oil into a container. Install and tighten the plug
after

the oil has been drained.

(4) Remove the engine pipe as described at the

end of this section.

(5) Remove the nuts and bolts retaining the

engine crossmember to the vehicle underbody and
withdraw the crossmember from the vehicle. On
automatic transaxle models, it will be necessary to
release the selector cable from the crossmember
bracket.

(6) Remove the sump retaining bolts and wash-

ers and if necessary firmly bump the sump with the
palm of the hand and remove it from the engine.

(7) Remove the bolts retaining the oil pump

pickup pipe to the oil pump and disconnect the
pickup pipe from the support bracket. Remove the
pickup pipe and discard the O ring seal.

(8) Remove the scraper and gasket from the

engine.

(9) Clean the gasket material from the sump,

engine block and the scraper.

NOTE: If the scraper assembly is damaged
it should be renewed.

TO INSTAL

(1) Wash the inside of the sump to remove

carbon and sludge deposits. Check for any metal
deposits which may indicate an imminent component
failure.

(2) Inspect the sump for dents and cracks.

Ensure that the gasket sealing face is not distorted or
damaged.

(3) Clean the pickup pipe screen with solvent

and a brush.

(4) Using a new O ring seal, install the pickup

pipe. Coat the pipe retaining bolts with Loctite 242
and tighten to the specified torque.

(5) Apply a bead of KP510-00150 sealer or

equivalent to the oil pump to cylinder block mating
joint area.

(6) Ensure that the sump gasket is correctly

located on the scraper and install the sump to
the
engine. Apply Loctite 242 to the threads of the sump
bolts and tighten the bolts to the specified torque.

(7) Install the front exhaust pipe using a

new
gasket and coat the threads of the flange nuts with an
anti-seize compound before tightening the nuts to the
specified torque.

(8) Install the engine crossmember and

tighten
the nuts and bolts securely. If applicable, connect the
automatic transaxle selector cable to the crossmember
bracket.

(9) Ensure that the sump drain plug is secure

and lower the vehicle to the ground.

(10) Fill the engine with the specified amount and

grade of engine oil. Refer to the Lubrication and
Maintenance section if necessary.

(11) Start and run the engine and check for oil

leaks.

View of the sump, oil pump pickup, gasket and scraper

removed from the engine.

Engine

9. OIL PUMP

TO REMOVE AND DISMANTLE

(1) Disconnect the negative battery terminal.
(2) Disconnect the lower radiator hose and drain

the cooling system.

(3) Raise the front of the vehicle and support it

on chassis stands. Refer to the Wheels and Tires
section if necessary.

(4) Remove the right hand front wheel.
(5) Remove the fasteners securing the engine

splash guard to the right hand front inner mudguard
and remove the splash guard.

(6) Remove the engine sump and oil pump

pickup pipe as previously described. Remove the oil
filter.

(7) Remove the camshaft timing belt as de-

scribed previously.

(8) Disconnect the oil pressure sender electrical

connector.

(9) Using a socket and bar, remove the bolt and

spacer retaining the crankshaft timing gear to the
crankshaft. Discard the bolt.

NOTE: It may be necessary to lock the
crankshaft when removing the crankshaft
timing gear retaining bolt. If necessary,
insert a piece of timber between the crank-
case and the crankshaft to prevent the
crankshaft turning.

(10) Remove the crankshaft timing gear from the

crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft.

(11) Remove the camshaft housing top cover.
(12) Using an open ended spanner, hold the

camshaft between the inlet and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.

(13) Remove the bolts securing the water pump

to the cylinder block and remove the water pump. If
necessary- refer to the Cooling and Heating Systems
section.

(14) Remove the camshaft drive belt inner cover

retaining bolts and remove the inner cover.

(15) Remove the bolts securing the oil pump to

Dismantled view of the oil pump assembly.

the cylinder block and remove the oil pump from the
engine. Discard the gasket.

(16) Remove the screws retaining the oil pump

cover plate and lift the cover plate from the rear of the
oil pump.

(17) Lift the inner and outer rotors from the oil

pump housing. Note that the outer rotor may be
stamped with a mark which must face the cover plate
on assembly.

(18) Unscrew the oil pressure relief valve plug

and remove the relief spring and plunger from the oil
pump housing. Discard the sealing washer from the
relief valve plug.

(19) If necessary, remove the oil pressure gauge

sender unit.

(20) Remove the crankshaft oil seal from the

pump housing.

TO CHECK AND INSPECT

(1) Wash all the pump components thoroughly

in cleaning solvent and allow to dry.

(2) Inspect the inner and outer rotors and the

cover plate for scoring or wear. Renew the rotors
and/or the cover plate if these faults are evident.

(3) Temporarily install the rotors into the oil

pump housing. Check the backlash between the teeth
of the inner and outer rotors at the point where the
rotor teeth are most closely meshed. If the clearance at
this point exceeds the Specifications, check the rotors
and housing for wear and renew as necessary.

(4) Check the rotor end float by placing a

straight edge across the oil pump housing and measure
the clearance between the straight edge and the rotors

View of the oil pump and associated components.

Engine

Checking the oil pump rotor end float.

with a feeler gauge. Renew the oil pump if this
clearance exceeds the Specifications.

(5) Check the cover plate for wear and scoring

and renew as necessary.

(6) Check the relief valve plunger and spring for

wear or damage. Renew any faulty components as
necessary.

TO ASSEMBLE AND INSTAL

Assembly is a reversal of the dismantling proce-

dure with attention to the following points:

(1) Liberally lubricate all components with clean

engine oil before assembly.

(2) Install the relief valve plunger and spring into

the pump housing and install the relief valve
plug
using a new sealing washer. Tighten the plug securely.

(3) Install the outer rotor into the pump housing

with the F mark on the rotor facing towards the cover
plate, if applicable. Install the inner rotor ensuring that
it is correctly meshed with the teeth of the outer rotor.

(4) Install the cover plate to the oil pump housing

and tighten the retaining screws to the specified
torque.

(5) Install a new oil seal to the front of the oil

pump housing. Ensure that the lip of the oil seal faces
the inside of the oil pump housing.

(6) If necessary, install the oil pressure gauge

sender unit.

(7) Turn the inner rotor in the oil pump housing.

Ensure that the oil pump rotates freely.

(8) Ensure that the mating surfaces of the oil

pump and cylinder block are thoroughly clean. Coat
the oil pump gasket with an oil resistant sealer and
install the oil pump and gasket to the cylinder block. It
may be necessary to turn the oil pump slightly to align
the inner rotor and crankshaft. Tighten the retaining
bolts to the specified torque.

NOTE: Ensure that the oil seal installed to
the oil pump is not damaged when the oil
pump is positioned on the crankshaft.

(9) Install the camshaft drive belt inner cover.
(10) Install the water pump using a new O ring.

Coat the water pump and the engine block mating
surfaces with Dow Corning silicone grease or equiva-
lent. Do not fully tighten the water pump retaining
bolls at this stage.

(11) Install the camshaft timing gear and tighten

the retaining bolt to the specified torque.

(12) Install the crankshaft timing gear spacer, key

and timing gear to the crankshaft.

(13) Using a new crankshaft timing gear retaining

bolt, install the spacer and tighten the retaining bolt to
the specified torque.

(14) Ensure that the oil pump pickup pipe and

screen are clean and free of foreign material. Install a
new O ring to the pipe and position the pickup pipe
and screen in position on the oil pump. Coat the
threads of the mounting bolts with Loctite 242 and
torque the bolts to the specified torque.

(15) Fill a new oil filter with the correct grade of

engine oil and install the oil filter.

(16) Install the sump as previously described.
(17) Install and adjust the camshaft drive belt as

described under the Camshaft Drive Belt heading.

(18) Fill the engine with the correct grade and

quantity of oil. Refer to the Lubrication and Mainte-
nance section.

(19) Fill the cooling system as described in the

Cooling and Heating Systems section.

(20) Start and run the engine and check for oil

and coolant leaks.

(21) Install the engine splash guard to the

inner
right hand mudguard.

(22) Install the right hand wheel and tighten the

wheel nuts as much as possible.

Checking the oil pump inner to outer rotor teeth

backlash.

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